Edward Carroll ed@ed-id.com +61 413 353 69 +61 7 3843 6751 87 Pampling St. Camp Hill QLD 4152
Education % Bachelor of Design (Honours) QUT, 2005-2009 - Major in Industrial Design, Minors in Interior Design and Marketing % Exchange Program (Masters Product Design) University of Leeds, United Kingdom 2009 % Work exhibited at: -New Designers Exhibition London -QUT Built Environment Open Days -University of Leeds Open Day
Skills % Ability to manage deadlines, cost, and quality on multiple projects
Experience BRASSFIT QUEENSLAND (IFS) – DESIGN LEAD- JANUARY 2010 – PRESENT
% Prioritising in busy environments while maintaining great working relationships to achieve successful quality outcomes on time and in budget.
% Design management, graphic design, 2D/3D CAD
% Professional communication and negotiation with various stakeholders.
% Goods Received and Purchasing Officer while maintaining budget.
% Traditional & digital sketching, concept generation, 3D modelling (surface/solid), modelmaking & photography % Design for manufacture: machining & fabrication drawings for high volume product runs, metal cold-working, hands-on CNC machining experience % Custom designing building fitouts in 2D & 3D and overseeing manufacture of facility.
% Project management (<5 principals)
% Creating and maintaining a working drawing library for over 2000 parts % Conducted a branding overhaul for the entire company % Implemented ISO 9001 certification standards for manufacturing design, safety and factory layouts. SHAKEDESIGN – DIRECTOR- AUGUST 2009-PRESENT
% Founder of 2D/3D design consultancy partnership.
% Instructional design, print graphics, branding, identity design, signage & stationery design
% Full product development methodologies coupled with solid graphic design expertise
% Software: Solidworks, AutoCAD, Sketchup, Photoshop, Illustrator, Indesign, Keyshot, Rhino3D, Mastercam, Toolpath, Sketchbook Pro, Final Cut Pro X, Microsoft Suite & Project
% Developed concepts from napkin sketches to manufacturable products % Broad experience in dealing with clients and manufacturers in Australia & Asia. % Innovation driven business approach ensuring great results MUIR’S TAEKWONDO – BRANCH INSTRUCTOR-2005-PRESENT
% Teaching taekwondo to all age groups, specialising in children’s classes % Managing syllabus and problem solving for students of all abilities % Helping grow branch from 40 to 110 + students weekly. % Logo redesign and brand overseer. 2
SHAKEDESIGN
Arm  Grinder
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Upper  Body  Cardio  Machine A complete product design and development cycle was undertaken in this project. From signing off on contracts to sketching, CAD to commerce, Chinese factories to challenging egos, the Arm Grinder Project had it all. edward  carroll  |  ed@ed-id.com
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Basis
Research
Users
Late 2009 saw the launch of ShakeDesign, run by myself and Mr. Alexandre Lasnier. The partnership was formed in response to an offer of collaboration with FitNance, a fitness machine development firm.
After reading Fitnance’s business plan, we set about conducting our own research. Shakedesign gained hands-on experience with the original Arm Grinder machine, and interviewed trainers and users of said machines.
Fitnance launched the original Arm Grinder in time for the successful World Cup 1999 Wallabies winning team. It was used before, during, and after this time, then transferred to the Queensland Reds. Steve Nance & Jeff Miller, the founders of FitNance, both have influential positions in rugby in Australia, and were in a position to launch their product within the best team in Australia.
We also travelled to gain first-hand experience with competing machines. (Please see the following page for details)
The primary users of the Arm Grinder are professional athletes in sports where upper body strength is paramount. Professional rugby clubs are the target market, with FitNance uniquely positioned to penetrate the upper echelons of Australian rugby.
Fast forward to 2009, and the aging Arm Grinders were no longer being used by the top teams. Competitor companies had launched their own upper body cardio machines, and FitNance was determined to come back to the top of the game.
A full SWOT analysis was conducted in tandem with a positioning matrix to highlight the values we were trying to attain. Our research led us to four key requirements for the design: it had to be tough, stable, reliable, and precise.
Fitnance engaged our services in the redesign of the Arm Grinder. The same basic principles of the original Grinder hadn’t changed, but a relaunch as a competitive top-level training aid was needed.
USER: PRO ATHLETE
ARM GRINDER REDESIGN Arm Grinder 2100
KRANKcycle AESTHETIC: BASIC
AESTHETIC: PROFESSIONAL
TotalCycle
USER: HOME USE TechnoGym
Positioning Matrix showing the desired market space for the redesigned arm grinder in relation to competitors.
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Upper body aerobic and anaerobic exercise are the primary functions of the machine. Athletes will use the Arm Grinder as a component of normal training sessions, as an off season tool, and as a way to participate in team training when a lower body injury is present. Secondary users are commercial gym members. Characteristics include weaker overall strength and availably of alternate machines (they aren’t told what to do by a coach). Secondary users also include wheelchair-bound trainees.
Arm Grinder 2100
Techno-Gym
SEG Superweigh Total Cycle
SEG Superweigh UG-7020
Currently in use at several Brisbane gyms, the prototype $UP *ULQGHU LV PDGH IURP D PRGLÀHG XSULJKW VWDWLRQDU\ bike.
Techno-Gym is a competitor product mainly used in rehabilitation and is targeted mainly towards commercial and outpatient use.
The total cycle is a full body cardio machine manufactured by SEG Superweigh in Ghangzhao, China. This product was torn down in order to determine the suitability of parts to use in redesign.
The UG-7020 is a high-performance commercial model stationary cycle. The mechanical components in the UG7020 were able to be used in the Arm Grinder redesign.
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Inspiration  for  this  project 7KLV PRRG ERDUG GHPRQVWUDWHV WKH LGHDOV DQG WKRXJKWV WKLV SRUMHFW ZDV EDVHG DURXQG 8VLQJ FOLHQW IHHGEDFN DQG UHVHDUFK WKH LGHDOV SUHVHQWHG KHUH GURYH WKH GHYHORSPHQW RI WKLV SURGXFW
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Drivewheel + Internals The internal mechanism of the Arm Grinder is re-used from the SEG UG $ QHZ FRQÀJXUDWLRQ ZDV QHHGHG LQ order to be used for upper body workouts.
Crankset + Display Assembly Saddle Base
Arm Grinder uses the SEG UG 7020 crankset. Designed for use in stationary bikes, it provides enough strength and resistance for the high performance users of this product.
Shakedesign chose to use the same seat post design provided by SEG. A typical bicycle seat was not appropriate, so a simple bench seat was designed.
A custom LCD screen provides workout feedback as well as enabling diagnostics.
Toe Wheels The simple hard compound wheels mean that the Grinder is stable when in use, and very easy to transport. edward carroll | ed@ed-id.com
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SHAKEDESIGN
Cardiotech VT-12
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Concept 1
Concept 2
Concept 3
Super-smooth A-surface, a large display area, and overall feminine form.
Integrated Hand grips, no-fuss surfacing, and retrostyled overall shape.
Stepped rugged edges, harsh bevelling, and a distinct hierarchy of utility.
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QUT
Ride-On Customs The final project of my QUT degree: Early childhood toys for contemporary Australians: I used sustainable practices to create generational and emotional attachment to loved products.
Ride-on Customs The skills exhibited here include design research, form development, surface modelling, compositing, sketching and rendering.
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The  Project
Research  Overview
For toys to be successful, the user (child) has to love them. A strong emotional connection must exist. A loved toy tends to be held onto, and not replaced. The product must be LOVED.
The toy car project was my final semester project while at QUT. The â&#x20AC;&#x2DC;problemâ&#x20AC;&#x2122; found through research was underdeveloped motor skills, and a lack of willingness to â&#x20AC;&#x2DC;hold onâ&#x20AC;&#x2122; to toys.
The ability for a toy to be educational is also paramount to success. Because children at this early age are still learning through doing, and still developing motor skills, a toy that does not stimulate as many senses as possible is often quickly cast away (Nezovic, 2009). A strong quality of LEARNING is essential.
Motor skills are divided up into two areas; fine motor skills and gross motor skills. Fine motor skills are what gives a child the ability to handle or manipulate small objects. Fine motor skills are required for things like drawing, writing painting, cutting and other more intricate tasks. Gross motor skills use more of the larger muscles along with balance and coordination.
A further criterion is for a product to have lifelong appeal. That is, the toy must not wear out before the child is done with it. I wanted to create a toy that will last several generations.
These skills give young children the ability to run, walk jump, roll, hop and other larger physical movements. Motor skills are an extremely important part of your childâ&#x20AC;&#x2122;s early. Some statistics say that approximately 15% of students attending primary schools experience motor difficulties. Also the ratio of boys to girls with a motor disability is 3:1.
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These statistics are staggering but an even more shocking statistic is one that says 60% of students also have problems in areas such as speech, short attention span, poor listening, poor self concept, abnormal or unacceptable behavior and general learning problems. A child can also be affected socially from lack of motor skills by being isolated or by having low self-esteem. An interesting correlation was found in that toys which both stimulate motor skills and allow modification were the most valued emotionally. The natural instinct of many children to customize their property was a very interesting field to explore.
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As an industry worth $23 000 000 000 annually in the US alone, the toy business is not unsaturated. No direct competitors were found at the time, making this a â&#x20AC;&#x2DC;new-to-marketâ&#x20AC;&#x2122; product.
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Inspiration &ORFNZLVH $XWRPREOR[ .R]\ .RXSH 'XSOR 0DWFKER[ &RQQHFWDEOHV 5DFHU 5DGLRĂ \HU 6NDJ %LNH Aid tool
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The initial model. This was an early attempt at surface modelling
Zebra stripes show where the curvature failed here. Time was running out, so the next iteration was simpler.
A much â&#x20AC;&#x2DC;blockierâ&#x20AC;&#x2122; model for revision 1.
Finally loaded into the CNC G-code generator after being sliced up in Solidworks.
CNC machine was set to a relatively low precision in order to speed up production.
Masking tape was a quick fastener for the foam mock-up. - Assembled and disassembled.
Initial  Model  Building  &  CAD Continuous curvature was not achieved initially, resulting in a complete restart of the modelling process. Once a rough apSUR[LPDWLRQ RI Ă&#x20AC;QDO VKDSH ZDV PRGHOOHG LW ZDV WKHQ HGLWHG WR be CNC routed. A vast amount of trouble shooting and problem solving had to be done to re-enable the CNC machine at QUT. Once the piece was made, it was quickly taped up and mocked together. User testing indicated that it had become grossly oversized, and so it was back to the drawing board. 18
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FEA testing within Solidworks helped keep the design realistic.
Curvature analysis allowed important decisions to be made about roto-moulding the parts.
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1
STEP
5
STEP
Assembly Steps: 1. Place core on ground 2. Slide nose tab into core 3. Slide tail tab into core
2
STEP
4. Screw seat into core, fastening tightly
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5. Align wheels with axle holes
STEP
6. Fasten with hand-bolts
3
STEP
4
STEP
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Life-Long Learning
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Loved
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UNIVERSITY Â OF Â LEEDS
electric  scooter  concept $V DQ HQWU\ IRU WKH DQQXDO -DPHV '\VRQ $ZDUG WKH H F\FOH ZDV GHVLJQHG WR DGGUHVV WZR SUREOHPV DLU SROOX WLRQ LQ $VLDQ XUEDQ FHQWUHV DQG WUDIÃ&#x20AC;F FRQJHVWLRQ :KLOH VFRRWHUV DUH DOUHDG\ FRPPRQSODFH IURP /RQGRQ WR 6HRXO WKH\ VWLOO SROOXWH WKH DLU DQG RXU HDUV 7KLV FRQFHSW DLPV WR VROYH WKRVH SUREOHPV
Zero  Emission  Vehicle The e-cycle is based off the Smart Wheel electric hub motor design. It combines elements of sport bikes and urban scooters in a new form. 22
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Brief
Tech
The User
The brief was simple – ‘Solve a problem’. Two problems that I believe are pressing are air pollution & congestion. Our planet can only support so much biomass, and there comes a point when we need to stop taking from it, and start giving.
The e-cycle zero personal transporter is what the Segway should have been. Innovative technology (in the form of in-wheel brushless DC electric motor) in a sleek, appealing shell, designed to solve the problems of today’s world.
Sunny was getting flustered again. She worked at an advertising agency, ran a yoga class, and had two young sons as well. Her husband Jay was just as busy. Between her work and home life, the only time she had to herself was sitting in traffic jams, stressing out and choking on the fumes from the other cars. Sometimes it seemed so difficult to stay ahead of the curve.
e-cycle zero was inspired by the failure of other forms of personal transport like the Segway and the Sinclair C5. A thorough analysis of both cases provided the research background to kick-start this project. While a mass manufactured electric scooter is not the final answer to this problem, I believe it is a step in the right direction. Congestion is also a big part of this. If an internal combustion vehicle is stopped in traffic, the engine still runs, and still emits carbon.
e-cycle zero is classified as a moped or motor scooter and is therefore licensed as such, so no confusion can arise. e-cycle zero is a single person transport with approximately 40 litres of luggage room in the compartment just forward of the rider. It has enough power to hit 100 kph in 4.9 seconds, and enough battery capacity to travel 100 kilometres between charging. e-cycle zero charges from a normal wall power outlet using a detachable lithium ion battery pack.
A Vespa or motorbike would help with the traffic jams and maybe provide a bit of fun in her life, but they still cost a bit. Another petrol tank to fill, more fumes in the face, not to mention hurting the environment more...
$3.7B
An electric vehicle produces no emissions during it’s running, and when it is stopped, it is stopped. Nothing is happening. While ICE vehicles are still appropriate for longer routes, especially in Australia, it is well and truly time for electric vehicles to take over city streets.
USD estimated cost of traffic congestion/year
4758tons carbon emission per km2 land mass/year in Korea
3,000,000 Privately owned cars in Seoul as of may 2011
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The James Dyson Award Presentation boards
Direction change:
Solidworks modelling
The E-cycle, initially called Bounce,was my entry for the Dyson Award competition while studying at University of Leeds. This concept was built around a frame, with coachwork added afterwards. The rake and overall stance of the bike was much larger and relaxed than the final iteration.
I changed the direction and entire shape of the cycle halfway through the timeframe allotted. My main reason for doing this was an error-riddled CAD model. All my parts were in place using the fix command, the geometry was not solid, and the bike was getting to be plain ugly.
The E-cycle was one of the first projects where I used surface modelling techniques. I moved away from the simple solid modelling (extrude, etc) and started experimenting in 3D sketches, splines, and flex commands.
The technology used to power the bike is the same - the wheel mounted brushless DC electric motor.
I started again from scratch, following much stricter conventions. My final CAD model ended up watertight, and much closer to my original design idea.
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This allowed me to create shapes which were previously unavailable to me... but also meant a whole new learning curve, which resulted in the initial model being scrapped!
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